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Quench Module Insert is a directional solidification furnace, which will fly in the Materials Science Research Facility. The QMI provides high thermal gradient and quench capabilities for processing metals and alloys in microgravity. This paper will describe the capabilities and present of on-going analysis and development testing.
The paper will describe the Development of a general three-dimensional multiple grid zone Navier-Stokes flowfield simulation program (ENS3D-MPP) designed for efficient execution on the Intel Paragon Massively Parallel Processor (MPP) supercomputer, and the subsequent application of this method to the prediction of the viscous flowfield about the V-22 Osprey tiltrotor vehicle. The flowfield simulation code solves the thin Layer or full Navier-Stoke's equation - for viscous flow modeling, or the Euler equations for inviscid flow modeling on a structured multi-zone mesh. In the present paper only viscous simulations will be shown. The governing difference equations are solved using a time marching implicit approximate factorization method with either TVD upwind or central differencing used for the convective terms and central differencing used for the viscous diffusion terms. Steady state or Lime accurate solutions can be calculated. The present paper will focus on steady state applications, although time accurate solution analysis is the ultimate goal of this effort. Laminar viscosity is calculated using Sutherland's law and the Baldwin-Lomax two layer algebraic turbulence model is used to compute the eddy viscosity. The Simulation method uses an arbitrary block, curvilinear grid topology. An automatic grid adaption scheme is incorporated which concentrates grid points in high density gradient regions. A variety of user-specified boundary conditions are available. This paper will present the application of the scalable and superscalable versions to the steady state viscous flow analysis of the V-22 Osprey using a multiple zone global mesh. The mesh consists of a series of sheared cartesian grid blocks with polar grids embedded within to better simulate the wing tip mounted nacelle. MPP solutions will be shown in comparison to equivalent Cray C-90 results and also in comparison to experimental data. Discussions on meshing considerations, wall clock execution time, load balancing, and scalability will be provided.
The Quench Module Insert is a directional solidification furnace that will operate in the Materials Science Research Rack (MSRR) on the International Space Station. It will provide high thermal gradient and quench capabilities for processing metals and alloys in microgravity. Numerical analyses and breadboard testing conducted to date show that the QMI can produce an axial temperature gradient approaching 150 C per centimeter in a 1 centimeter diameter aluminum sample with a maximum molten sample temperature of 1100 C. Breadboard testing and analysis have also shown that the quench capabilities of the furnace are sufficient to rapidly solidify at least a 5mm axial portion of a 1 centimeter diameter molten aluminum sample in significantly less than the required 2 seconds and prevent significant backmelt. This paper presents the furnace requirements and capabilities and a status of the associated development testing and analyses.
An overview of the current state-of-the-art in computational aeroacoustics as applied to fan noise prediction at NASA Glenn is presented. Results from recent modeling efforts using three dimensional inviscid formulations in both frequency and time domains are summarized. In particular, the application of a frequency domain method, called LINFLUX, to the computation of rotor-stator interaction tone noise is reviewed and the influence of the background inviscid flow on the acoustic results is analyzed. It has been shown that the noise levels are very sensitive to the gradients of the mean flow near the surface and that the correct computation of these gradients for highly loaded airfoils is especially problematic using an inviscid formulation. The ongoing development of a finite difference time marching code that is based on a sixth order compact scheme is also reviewed. Preliminary results from the nonlinear computation of a gust-airfoil interaction model problem demonstrate the fidelity and accuracy of this approach. Spatial and temporal features of the code as well as its multi-block nature are discussed. Finally, latest results from an ongoing effort in the area of arbitrarily high order methods are reviewed and technical challenges associated with implementing correct high order boundary conditions are discussed and possible strategies for addressing these challenges ore outlined.
Rim cracking in turbine wheels with welded blades was evaluated. The problem is explained on the basis of the occurrence of plastic flow in the rim during transient starting conditions when thermal compressive stresses resulting from high-temperature gradients exceed the proportional elastic limit of the material.
The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition1 invented at the NASA Glenn Research Center: Cu-8(at.%)Cr-4%Nb. Many of the properties of this alloy have been shown to be far superior to those of other conventional copper alloys, such as NARloy-Z. Despite this considerable advantage, it is expected that GRCop-84 will suffer from some type of environmental degradation depending on the type of rocket fuel utilized. In a liquid hydrogen (LH2), liquid oxygen (LO2) booster engine, copper alloys undergo repeated cycles of oxidation of the copper matrix and subsequent reduction of the copper oxide, a process termed "blanching". Blanching results in increased surface roughness and poor heat-transfer capabilities, local hot spots, decreased engine performance, and premature failure of the liner material. This environmental degradation coupled with the effects of thermomechanical stresses, creep, and high thermal gradients can distort the cooling channel severely, ultimately leading to its failure.
A computational conjugate heat transfer methodology was developed, as a first step towards an efficient and accurate multiphysics, thermo-fluid computational methodology to predict environments for hypothetical solid-core, nuclear thermal engine thrust chamber and components. A solid conduction heat transfer procedure was implemented onto a pressure-based, multidimensional, finite-volume, turbulent, chemically reacting, thermally radiating, and unstructured grid computational fluid dynamics formulation. The conjugate heat transfer of a cylindrical material specimen heated by an impinging hot hydrogen jet inside an enclosed test fixture was simulated and analyzed. The solid conduction heat transfer procedure was anchored with a standard solid heat transfer code. Transient analyses were then performed with ,variable thermal conductivities representing three composites of a material utilized as flow element in a legacy engine test. It was found that material thermal conductivity strongly influences the transient heat conduction characteristics. In addition, it was observed that high thermal gradient occur inside the cylindrical specimen during an impulsive or a 10 s ramp start sequence, but not during steady-state operations.
Analysis of Direct Numerical Simulations (DNS) transitional states of temporal, supercritical mixing layers for C7H16/N2 and O2/H2 shows that the evolution of all layers is characterized by the formation of high-density-gradient magnitude (HDGM) regions.
study was done as part of an effort to develop computational models representing turbulent mixing under thermodynamic supercritical (here, high pressure) conditions. The question was whether the large-eddy simulation (LES) approach, developed previously for atmospheric-pressure compressible-perfect-gas and incompressible flows, can be extended to real-gas non-ideal (including supercritical) fluid mixtures. [In LES, the governing equations are approximated such that the flow field is spatially filtered and subgrid-scale (SGS) phenomena are represented by models.] The study included analyses of results from direct numerical simulation (DNS) of several such mixing layers based on the Navier-Stokes, total-energy, and conservation- of-chemical-species governing equations. Comparison of LES and DNS results revealed the need to augment the atmospheric- pressure LES equations with additional SGS momentum and energy terms. These new terms are the direct result of high-density-gradient-magnitude regions found in the DNS and observed experimentally under fully turbulent flow conditions. A model has been derived for the new term in the momentum equation and was found to perform well at small filter size but to deteriorate with increasing filter size. Several alternative models were derived for the new SGS term in the energy equation that would need further investigations to determine if they are too computationally intensive in LES.
Thermal protection materials used in spacecraft heatshields are subjected to severe thermal and mechanical loading environments during re-entry into earth atmosphere. In order to investigate the reliability of PICA tiles in the presence of high thermal gradients as well as mechanical loads, the authors designed and conducted solar-tower tests. This paper presents the design and analysis work for this tests series. Coupled non-linear thermal-mechanical finite element analyses was conducted to estimate in-depth temperature distribution and stress contours for various cases. The first set of analyses performed on isolated PICA tile showed that stresses generated during the tests were below the PICA allowable limit and should not lead to any catastrophic failure during the test. The tests results were consistent with analytical predictions. The temperature distribution and magnitude of the measured strains were also consistent with predicted values. The second test series is designed to test the arrayed PICA tiles with various gap-filler materials. A nonlinear contact method is used to model the complex geometry with various tiles. The analyses for these coupons predict the stress contours in PICA and inside gap fillers. Suitable mechanical loads for this architecture will be predicted, which can be applied during the test to exceed the allowable limits and demonstrate failure modes. Thermocouple and strain-gauge data obtained from the solar tower tests will be used for subsequent analyses and validation of FEM models.
Because advanced SiC/SiC composites are projected to be used for aerospace components with large thermal gradients at high temperatures, efforts are on-going at NASA Glenn to develop approaches for modeling the anticipated creep behavior of these materials and its subsequent effects on such key composite properties as internal residual stress, proportional limit stress, ultimate tensile strength, and rupture life. Based primarily on in-plane creep data for 2D panels, this presentation describes initial modeling progress at applied composite stresses below matrix cracking for some high performance SiC/SiC composite systems recently developed at NASA. Studies are described to develop creep and rupture models using empirical, mechanical analog, and mechanistic approaches, and to implement them into finite element codes for improved component design and life modeling
Motivated by large eddy simulation (LES) modeling of supercritical turbulent flows, transitional states of databases obtained from direct numerical simulations (DNS) of binary-species supercritical temporal mixing layers were examined to understand the subgrid-scale dissipation, and its variation with filter size. Examination of the DSN-scale domain- averaged dissipation confirms previous findings that, out of the three modes of viscous, temperature and species-mass dissipation, the species-mass dissipation is the main contributor to the total dissipation. The results revealed that the percentage of species-mass by total dissipation is nearly invariant across species systems and initial conditions. This dominance of the species-mass dissipation is due to high-density-gradient magnitude (HDGM) regions populating the flow under the supercritical conditions of the simulations; such regions have also been observed in fully turbulent supercritical flows. The domain average being the result of both the local values and the extent of the HDGM regions, the expectations were that the response to filtering would vary with these flow characteristics. All filtering here is performed in the dissipation range of the Kolmogorov spectrum, at filter sizes from 4 to 16 times the DNS grid spacing. The small-scale (subgrid scale, SGS) dissipation was found by subtracting the filtered-field dissipation from the DNS-field dissipation. In contrast to the DNS dissipation, the SGS dissipation is not necessarily positive; negative values indicate backscatter. Backscatter was shown to be spatially widespread in all modes of dissipation and in the total dissipation (25 to 60 percent of the domain). The maximum magnitude of the negative subgrid- scale dissipation was as much as 17 percent of the maximum positive subgrid- scale dissipation, indicating that, not only is backscatter spatially widespread in these flows, but it is considerable in magnitude and cannot be ignored for the purposes of LES modeling. The Smagorinsky model, for example, is unsuited for modeling SGS fluxes in the LES because it cannot render backscatter. With increased filter size, there is only a modest decrease in the spatial extent of backscatter. The implication is that even at large LES grid spacing, the issue of backscatter and related SGS-flux modeling decisions are unavoidable. As a fraction of the total dissipation, the small-scale dissipation is between 10 and 30 percent of the total dissipation for a filter size that is four times the DNS grid spacing, with all OH cases bunched at 10 percent, and the HN cases spanning 24 30 percent. A scale similarity was found in that the domain-average proportion of each small-scale dissipation mode, with respect to the total small-scale dissipation, is very similar to equivalent results at the DNS scale. With increasing filter size, the proportion of the small-scale dissipation in the dissipation increases substantially, although not quite proportionally. When the filter size increases by four-fold, 52 percent for all OH runs, and 70 percent for HN runs, of the dissipation is contained in the subgrid-scale portion with virtually no dependence on the initial conditions of the DNS. The indications from the dissipation analysis are that modeling efforts in LES of thermodynamically supercritical flows should be focused primarily on mass-flux effects, with temperature and viscous effects being secondary. The analysis also reveals a physical justification for scale-similarity type models, although the suitability of these will need to be confirmed in a posteriori studies.
The distant future of mankind and the ultimate survivability of the human race, as it is known today, will depend on mans' ability to break earthly bonds and establish new territorial positions throughout the universe. Man must therefore be positioned to not only travel to, but also, to readily adapt to numerous and varying environments. For this mass migration across the galaxies nothing is as import to the human race as is NASA's future missions into Low Earth Orbit (LEO), to the moon, and/or Mars. These missions will form the building blocks to eternity for mankind. From these missions, NASA will develop the foundations for these building blocks based on sound engineering and scientific principles, both known and yet to be discovered. The integrity of the program will lead to development, tracking and control of the most basic elements of hardware production: That being development and control of applications of space flight materials. Choosing the right material for design purposes involves many considerations, such as governmental regulations associated with manufacturing operations, both safety of usage and of manufacturing, general material usage requirements, material longevity and performance requirements, material interfacing compatibility and material usage environments. Material performance is subject to environmental considerations in as much as a given material may perform exceptionally well at standard temperatures and pressures while performing poorly under non-standard conditions. These concerns may be found true for materials relative to the extreme temperatures and vacuum gradients of high altitude usage. The only way to assure that flight worthy materials are used in design is through testing. However, as with all testing, it requires both time on schedule and cost to the operation. One alternative to this high cost testing approach is to rely on a materials control system established by NASA. The NASA community relies on the MAPTIS materials control system founded at MSFC and supported by the other NASA Centers. This system is a data bank of all materials used in space flight operations. These materials are rated for several characteristics that are common concerns in high altitude or deep space usage: Odor, off gassing, material fluid compatibility, toxicity, corrosion susceptibility, stress corrosion susceptibility, etc.
This paper describes recent development of environmental barrier coatings on SiC/SiC ceramic matrix composites. The creep and fatigue behavior at aggressive long-term high temperature conditions have been evaluated and highlighted. Thermal conductivity and high thermal gradient cyclic durability of environmental barrier coatings have been evaluated. The damage accumulation and complex stress-strain behavior environmental barrier coatings on SiCSiC ceramic matrix composite turbine airfoil subelements during the thermal cyclic and fatigue testing of have been also reported.
Variable-Domain Displacement Transfer Functions were formulated for shape predictions of complex wing structures, for which surface strain-sensing stations must be properly distributed to avoid jointed junctures, and must be increased in the high strain gradient region. Each embedded beam (depth-wise cross section of structure along a surface strain-sensing line) was discretized into small variable domains. Thus, the surface strain distribution can be described with a piecewise linear or a piecewise nonlinear function. Through discretization, the embedded beam curvature equation can be piece-wisely integrated to obtain the Variable-Domain Displacement Transfer Functions (for each embedded beam), which are expressed in terms of geometrical parameters of the embedded beam and the surface strains along the strain-sensing line. By inputting the surface strain data into the Displacement Transfer Functions, slopes and deflections along each embedded beam can be calculated for mapping out overall structural deformed shapes. A long tapered cantilever tubular beam was chosen for shape prediction analysis. The input surface strains were analytically generated from finite-element analysis. The shape prediction accuracies of the Variable- Domain Displacement Transfer Functions were then determined in light of the finite-element generated slopes and deflections, and were fofound to be comparable to the accuracies of the constant-domain Displacement Transfer Functions
Sea surface temperature (SST) studies are often focused on improving accuracy, or understanding and quantifying uncertainties in the measurement, as SST is a leading indicator of climate change and represents the longest time series of any ocean variable observed from space. Over the past several decades SST has been studied with the use of satellite data. This allows a larger area to be studied with much more frequent measurements being taken than direct measurements collected aboard ship or buoys. The Group for High Resolution Sea Surface Temperature (GHRSST) is an international project that distributes satellite derived sea surface temperatures (SST) data from multiple platforms and sensors. The goal of the project is to distribute these SSTs for operational uses such as ocean model assimilation and decision support applications, as well as support fundamental SST research and climate studies. Examples of near real time applications include hurricane and fisheries studies and numerical weather forecasting. The JPL group has produced a new 1 km daily global Level 4 SST product, the Multiscale Ultrahigh Resolution (MUR), that blends SST data from 3 distinct NASA radiometers: the Moderate Resolution Imaging Spectroradiometer (MODIS), the Advanced Very High Resolution Radiometer (AVHRR), and the Advanced Microwave Scanning Radiometer ? Earth Observing System(AMSRE). This new product requires further validation and accuracy assessment, especially in coastal regions.We examined the accuracy of the new MUR SST product by comparing the high resolution version and a lower resolution version that has been smoothed to 19 km (but still gridded to 1 km). Both versions were compared to the same data set of in situ buoy temperature measurements with a focus on study regions of the oceans surrounding North and Central America as well as two smaller regions around the Gulf Stream and California coast. Ocean fronts exhibit high temperature gradients (Roden, 1976), and thus satellite data of SST can be used in the detection of these fronts. In this case, accuracy is less of a concern because the primary focus is on the spatial derivative of SST. We calculated the gradients for both versions of the MUR data set and did statistical comparisons focusing on the same regions.
The first steps for In Situ Resource Utilization (ISRU) on target bodies such as the Moon, Mars and Near Earth Asteroids (NEA), and even comets, involve the same sequence of steps as in the terrestrial mining of resources. First exploration including prospecting must occur, and then the resource must be acquired through excavation methods if it is of value. Subsequently a load, haul and dump sequence of events occurs, followed by processing of the resource in an ISRU plant, to produce useful commodities. While these technologies and related supporting operations are mature in terrestrial applications, they will be different in space since the environment and indigenous materials are different than on Earth. In addition, the equipment must be highly automated, since for the majority of the production cycle time, there will be no humans present to assist or intervene. This space mining equipment must withstand a harsh environment which includes vacuum, radical temperature swing cycles, highly abrasive lofted dust, electrostatic effects, van der Waals forces effects, galactic cosmic radiation, solar particle events, high thermal gradients when spanning sunlight terminators, steep slopes into craters / lava tubes and cryogenic temperatures as low as 40 K in permanently shadowed regions. In addition the equipment must be tele-operated from Earth or a local base where the crew is sheltered. If the tele-operation occurs from Earth then significant communications latency effects mandate the use of autonomous control systems in the mining equipment. While this is an extremely challenging engineering design scenario, it is also an opportunity, since the technologies developed in this endeavor could be used in the next generations of terrestrial mining equipment, in order to mine deeper, safer, more economical and with a higher degree of flexibility. New space technologies could precipitate new mining solutions here on Earth. The NASA KSC Swamp Works is an innovation environment and methodology, with associated laboratories that uses lean development methods and creativity-enhancing processes to invent and develop new solutions for space exploration. This paper will discuss the Swamp Works approach to developing space mining and resource extraction systems and the vision of space development it serves. The ultimate goal of the Swamp Works is to expand human civilization into the solar system via the use of local resources utilization. By mining and using the local resources in situ, it is conceivable that one day the logistics supply train from Earth can be eliminated and Earth independence of a space-based community will be enabled.
Data assimilation of Aerosol Robotic Network (AERONET) and Moderate Resolution Imaging Spectroradiometer (MODIS) aerosol optical thickness (AOT) for aerosol forecasting was tested within the Navy Aerosol Analysis Prediction System (NAAPS) framework, using variational and ensemble data assimilation methods. Navy aerosol forecasting currently makes use of a deterministic NAAPS simulation coupled to Navy Variational Data Assimilation System for aerosol optical depth, a two-dimensional variational data assimilation system, for MODIS AOT assimilation. An ensemble version of NAAPS (ENAAPS) coupled to an ensemble adjustment Kalman filter (EAKF) from the Data Assimilation Research Testbed was recently developed, allowing for a range of data assimilation and forecasting experiments to be run with deterministic NAAPS and ENAAPS. The main findings are that the EAKF, with its flow-dependent error covariances, makes better use of sparse observations such as AERONET AOT. Assimilating individual AERONET observations in the two-dimensional variational system can increase the analysis errors when observations are located in high AOT gradient regions. By including AERONET with MODIS AOT assimilation, the magnitudes of peak aerosol events (AOT> 1) were better captured with improved temporal variability, especially in India and Asia where aerosol prediction is a challenge. Assimilating AERONET AOT with MODIS had little impact on the 24 h forecast skill compared to MODIS assimilation only, but differences were found downwind of AERONET sites. The 24 h forecast skill was approximately the same for forecasts initialized with analyses from AERONET AOT assimilation alone compared to MODIS assimilation, particularly in regions where the AERONET network is dense; including the United States and Europe, indicating that AERONET could serve as a backup observation network for over-land synoptic-scale aerosol events.